FIELD OF INVENTION
[001]The present subject matter described herein, relates to a front bumper beam structure for vehicle, and, in particular, to a three piece bumper beam structure of the vehicle to absorb impact energy thus protecting leg of pedestrian and protecting front end systems like lamps radiator, condenser during Low speed impact.
BACKGROUND AND PRIOR ART:
[002] Vehicle manufacturers are concerned with improving passenger safety and with reducing the cost of repairing vehicles in the event of impacts, while at the same time avoiding any significant increase in the weight of these vehicles.
[003] For pedestrian safety, in the event of a frontal impact, manufacturers are optimizing the various parts, such front bumper of the vehicle. The bumper system has an energy absorber which absorbs energy during pedestrian impact with the vehicle. There are several zones, such as upper leg and lower leg where vehicle hit the pedestrian. The upper leg energy absorber is provided at the upper side of the bumper where upper part of radiator is mounted. Further, the lower leg energy absorber is provided at lower side where lower part of the radiator is mounted. Along with the pedestrian safety, the manufactures has to protect the functional parts from the impact. Accordingly, the manufactures provide several stiffer zones in the bumper system to avoid transmission of impact energy to functional parts. The manufactures provide front extending member which extend along length of the vehicle and define engine cabin.
[004] However, given the limited space in motor vehicles, manufacturers, have to develop structures which guarantee a good level of energy absorption from the end of the vehicle up to the non-deformable zone while at the same time avoiding dead zones, that is to say zones which cannot deform axially and absorb significant deformation work.

[005] In order to reduce the cost of repair during low speed impact, the manufacturers modify the bumpers or the scuff moldings of the vehicles, particularly by strengthening the bumper beam and inserting deformable mechanical elements known as energy absorbers which are designed to crumple under a force which is appreciably lower than the force required to deform the bumper beam. But by adding energy absorbers in the bumper beam adds extra cost and weight to the bumper beams.
[006] Further, the existing bumper beams has box structure at the terminal ends to absorb impact energy during low speed impact and the frontal pedestrian impact. The box structures in the bumper beam have a plurality of parts which makes the structure more complex and costly. The bumper beam having the energy absorbers has to work efficiently in all direction with respect to angles of impact. To cater angles of the impact, the bumper beam has a plurality of crushable lobes along front surface of the bumper beam. In the system, quality of resin and placement of crushable lobes plays important role. Further, it adds extra cost and weight to the bumper beam system.
[007] In an attempt to satisfy these criteria, numerous solutions have been implemented to date, but they lead to an appreciable increase in the weight of the vehicle and in cost.
[008] One solution to avoid this drawback, energy absorbers are known which are made of aluminum, which allows the weight to be reduced, but their energy-absorption properties are generally not easy to control and often insufficient, while the material costs and cost of manufacture of such absorbers remain high.
[009] Further, the energy absorption box structures at terminal end is complex and required multiple parts. These box structures absorbs impact energy. However their cost of manufacture also remains very high and along with weight.
[0010] In order to improve the energy absorbing efficiency of the front bumper, sometime foam based absorbers are positioned in between the bumper and the vehicle long members.

[0011] Adding of these absorbers results in the cost and weight of the bumper assembly of the vehicle which reduces the overall efficiency of the vehicle. The existing energy absorbers are expensive and complex in designing and manufacturing. Therefore, there is a need in the art to have a bumper beam structure that can be more simple and inexpensive, and which can absorb the impact energy based on the location and force of impact imparted to the pedestrian's lower leg.
OBJECTS OF THE INVENTION:
[0012] The principal objective of the present invention is to provide a front bumper beam structure for absorbing impact energy in the event of pedestrian collision with vehicle front end.
[0013] Another object of the present subject matter is to provide a front bumper beam structure to protect front end components of engine cabin in the event of Low speed impact.
[0014] Another object of the present subject matter is to provide a three piece front bumper beam structure to compliance with pedestrian safety and low speed impact regulations.
[0015] Another object of the present subject matter is to provide a three piece front bumper beam having light weight.
[0016] Yet another object of the present invention is to provide a bumper beam structure which is simple and inexpensive, and efficiently absorbs the impact energy without major injury to leg of the pedestrian and front end components.
SUMMARY OF THE INVENTION:
[0017] The subject matter disclosed herein relates to a three piece bumper beam structure to protect pedestrian leg during impact of the vehicle with pedestrian and to protect front end systems, such as cooling unit or radiator or lamps during Low speed impact, The three piece bumper beam structure comprises a bumper beam, a right side terminal end bracket and a left side terminal end bracket. The bumper beam is joined in between the right side terminal end bracket and the left side

terminal end bracket through spot welding. Further, the right side terminal end bracket and the left side terminal end bracket are mounted on long members of the vehicle body through bolts. The present three piece bumper beam structure is made from sheet metal thus having light weight and low cost.
[0018] In an embodiment, the terminal bracket whether right side or left side comprises a base portion, vertical portion and a top portion. The base portion has a plurality of mounting holes to mount the terminal end bracket on the long members of the vehicle body. The vertical portion extends at an angle from the base portion in upward direction. The top portion extends in perpendicular direction from the vertical portion to receive the bumper beam. The terminal brackets are mounted on the long members of the vehicle body. The terminal brackets have a bumper beam in middle which expands along width of the vehicle.
[0019] In order to further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit scope of the present subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:

[0021] Fig. 1 illustrates mounting of front bumper beam on long members of the vehicle at front end, in accordance with an embodiment of the present subject matter;
[0022] Fig. 2 illustrates exploded view of three piece front bumper beam, in accordance with an embodiment of the present subject matter;
[0023] Fig. 3 illustrates assembled view of the three piece front bumper beam, in accordance with an embodiment of the present subject matter;
[0024] Fig. 4 illustrates structure of terminal end members of the three piece bumper beam structure, in accordance with an embodiment of the present subject matter;
[0025] Fig. 5a and 5b illustrates deformation pattern in the terminal end members during pedestrian impact, in accordance with an embodiment of the present subject matter; and
[0026] Fig. 6a and 6b illustrates deformation pattern in the terminal end members during Low speed impact, in accordance with an embodiment of the present subject matter.
[0027] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0028] The subject matter disclosed herein relates to a three piece bumper beam structure to protect pedestrian leg during impact of the vehicle with pedestrian and to protect front end systems, such as cooling unit or radiator or lamps during Low speed impact, The three piece bumper beam structure comprises a bumper beam, a right side terminal end bracket and a left side terminal end bracket. The bumper beam is joined in between the right side terminal end bracket and the left side terminal end bracket through spot welding. Further, the right side terminal end

bracket and the left side terminal end bracket are mounted on long members of the vehicle body through bolts. The present three piece bumper beam structure is made from sheet metal thus having light weight and low cost.
[0029] In an embodiment, the terminal bracket whether right side or left side comprises a base portion, vertical portion and a top portion. The base portion has a plurality of mounting holes to mount the terminal end bracket on the long members of the vehicle body. The vertical portion extends at an angle from the base portion in upward direction. The top portion extends in perpendicular direction from the vertical portion to receive the bumper beam. The terminal brackets are mounted on the long members of the vehicle body. The terminal brackets have a bumper beam in middle which expands along width of the vehicle.
[0030] On the present energy absorber, a plurality of beads is provided on the complete surface of the energy absorber at equal distance along the length. Each of the beads from the plurality of beads is provided at equal distance from each other. Further, no hole is provided in the corner zone which gives highest stiffness to this zone. During the impact the corner zone requires higher stiffness compared to the central and middle zone so that pedestrian leg does not come in contact with hard structural members at corners.
[0031] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be

construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0032] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0033] FIGS. 1 to 3 illustrate the three piece bumper beam satisfying pedestrian safety and Low speed impact regulations of the present subject matter. The present three piece bumper beam can be mounted on any vehicle that meets the pedestrian safety regulations. The present beam structure is intended to reduce the impact force of a vehicle on a pedestrian when the pedestrian and vehicle impact. The present beam structure also reduces intrusion into the vehicle when the bumper and an object impact each other at Low speed, either when the object is a flat surface or an angled surface. The present beam structure can be mounted on the front frame or rear frame of a vehicle. In particular, the beam structure can be mounted on the bumper area of the front of the vehicle. In the present beam structure is mounted transversally on the vehicle along width of the vehicle.
[0034] Fig. 1 illustrates mounting of the present three piece bumper beam across width of the vehicle, in accordance with an embodiment of the present subject matter. The present assembly 100 includes two long members 103, 104 running along length of the vehicle. On the long members 103, 104, the three piece bumper beam structure is mounted with screws or bolts. The three piece bumper beam structure comprises three parts, i.e., bumper beam 101, right side terminal end bracket 102, and left side terminal end bracket 103. The bumper beam 101 is

provided in between the right side terminal end bracket 102 and the left side terminal end bracket 103. Detail description of the three piece structure is explained in the figure 2. In an embodiment, the three piece bumper beam structure is mounted on front end of the vehicle to absorb impact energy from all directions during pedestrian impact with the vehicle.
[0035] Referring to figure 2 illustrating exploded view of the three piece bumper beam structure 200. The three piece bumper beam structure 200 includes a bumper beam 201, a right side terminal end bracket 203 and left side terminal end bracket 202. Both the right side terminal end bracket 203 and the left side terminal end bracket 202 are similar in shape, configuration and dimensions, therefore, hereinafter both can be interchangeably referred as terminal end brackets 202, 203. The bumper beam 201 is disposed in between the right side terminal end bracket 203 and the left side terminal end bracket 202. The bumper beam 201 is spot welded on the terminal end brackets 202, 203. The bumper beam 201 is provided transversally along width of the vehicle to cover complete width of the vehicle. The bumper beam 201 has a rectangular bead 201a along length of the bumper beam 201. The rectangular bead 201a provides strength to the bumper beam 201 and avoids to and fro motion of the bumper beam along length of the vehicle. The rectangular bead 201a helps to absorb force of impact in frontal Impact.
[0036] Referring to figure 3, the bumper beam 201 is joined with the terminal end brackets 202, 203 through spot welding. Further, the terminal end brackets 202, 203 having the bumper beam 201 in middle are mounted on the main body of the vehicle through bolts.
[0037] Referring to figure 5a, the terminal end bracket 500 includes a base portion
501 having a plurality of mounting holes 501a, 501b to mount the terminal end bracket 500 on the long membersl03, 104 of the vehicle body. A vertical portion
502 extends at an angle from the base portion 501 in upward direction. The angle is in range 45° to 120°, preferably 60° to 90°. Further, a top portion 503 extends perpendicularly in forward direction from the vertical portion 502 to receive the

bumper beam 201. Other terminal bracket has similar structure and shape. The base portion 501, the vertical portion 502 and the top portion 503 define a ‘S’ shape terminal end bracket where end portions are flat to receive the bumper beam and to mount the terminal bracket on the long members of the vehicle. Referring 5 to figure 4, the base portion 501 and the vertical portion 502 have a continuous bead 504 in shape of triangle to prevent deformation of the bumper beam 201 during the Low speed impact. The continuous bead 504 extends from the base portion 501 to the vertical portion 502. Further, the triangular continuous bead 504 has wider base or base in the base portion 501 and narrow portion in the 10 vertical portion 502. In other words, the triangular continuous bead 504 tapered down from the base portion 501 to the vertical portion 502.
[0038] In an embodiment as disclose in the figure 4, the vertical portion 502 and the top portion 503 has continuous beads 505, 506 at corners to provide strength at corner to avoid sharp bending of the top portion 503. The continuous beads 15 505, 506 deform during pedestrian impact to absorb force of impact.
[0039] Referring back to figure 3 which illustrates impact of force in three directions, such as L1, L2 and L3. Where in , L2 and L3 represents the different impact load positions at the front of the vehicle.
[0040] In case of pedestrian impact at L1 L1, when the force acts on the bumper 20 beam, the force transmits to the apron member or long members through terminal brackets 202, 203. The terminal brackets 202, 203 have mainly three continuous bead structures 504, 505, 506, as shown in the figure 4. In case of the pedestrian impact, the deformation happens in 505 and 506 simultaneously, absorbing the force of impact to protect the pedestrian leg. The present bead structures, i.e., 505 25 and 506 of the terminal brackets guides the deformation of the terminal bracket 500 in such a way so that energy is not transmitted to the pedestrian leg. Referring to figure 5b, the terminal bracket 500 is in straight position 507 before the pedestrian impact with the vehicle. After the pedestrian impact with the vehicle, the beads structure 505, 506 guides bending of the terminal bracket 500 towards
10

inward direction to absorb impact energy. Reference numeral 508 shows the bending of the terminal bracket 500 toward inward direction.
[0041] In case of low speed impact atL2, the bead structure 504 acts as another element to absorb energy and guides the deformation in such a way that the 5 bumper beam structure 201 is not bent towards the engine room side. This helps in protection of the Engine Cooling units.
[0042] In the event of Low speed impact at L3 the entire load is transferred laterally in the bumper beam structure 201. The continuous bead Structure 504 then prevents the deformation in such a way that the bumper beam 201 is not bent
10 towards the engine room side. This helps in protection of the Engine Cooling units. The terminal end bracket bent in outward direction stretch the bumper beam so that the bumper beam do not hit the engine cooling unit. Figure 6a and 6b illustrate position of the terminal end bracket before and after impact. Reference numeral 601 shows structure of the terminal end bracket before impact and
15 reference numeral 602 indicates structure of the terminal end bracket after the impact.
[0043] The present three piece bumper beam structure is made of sheet metal which results in light weight and low cost. Further, bead structures 504, 505, 506 can be provided on the terminal brackets easily by the pressing machine. Another
20 advantage of the present three piece bumper beam structure is that if any part be it right side terminal end bracket, bumper beam, and left side terminal end bracket is damaged in corresponding side impact, during serviceability, only the damaged part can be replaced with fresh part other parts may remain same. Therefore, serviceability cost is reduced. Further, the present structure uses simple spot
25 welding process to join the bumper beam with the terminal brackets which involve low cost.
[0044] In another embodiment of the present subject matter, the shape and number of bead structures in the terminal brackets can be optimized to provide more strength and stiffness to the terminal brackets.
11

[0045] The term "vehicle" or "Automobile" as used throughout this detailed description and in the claims refers to any moving vehicle that is capable of carrying one or more human occupants or Goods and is powered by any form of energy. The term "vehicle" is a motor vehicle which includes, but is not limited to: cars, trucks, vans, minivans, hatchback, sedan, MUVs, and SUVs.
[0046] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of "comprising" or "including" also contemplates embodiments that "consist essentially of or "consist of the recited feature.
[0047] Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.

We claim:
1.A three piece bumper beam structure (200) to protect pedestrian leg during impact of the vehicle with pedestrian and to protect front end systems during Low speed impact, the three piece bumper beam structure (200) comprising:
a bumper beam (201);
a right side terminal end bracket (203) and a left side terminal end bracket (202);
wherein the bumper beam (201) is joined to the right side terminal end bracket (203) and the left side terminal end bracket (202);
wherein the right side terminal end bracket (203) and the left side terminal end bracket (202) are mounted on long members (103, 104) of the vehicle body.
2. The three piece bumper beam structure (200) as claimed in claim 1, wherein the bumper beam (201) is provided transversally along width of the vehicle.

3. The three piece bumper beam structure (200) as claimed in claim 1, wherein the bumper beam (201) is spot welded on the right side terminal end bracket (203) and the left side terminal end bracket (202).

4. The three piece bumper beam structure (200) as claimed in claim 1, wherein the right side terminal end bracket (203) and the left side terminal end bracket (202) are of ‘S’ shape brackets (202, 203).

5. The three piece bumper beam structure (200) as claimed in claim 4, wherein the right and left side terminal end bracket (202, 203, 500) comprises:
a base portion (501) having a plurality of mounting holes (501a, 501b) to mount the terminal end bracket (202, 203, 501) on the long members (103, 104) of the vehicle body;
a vertical portion (502) extends at an angle from the base portion (501) in upward direction;
a top portion (503) extends forward in perpendicular direction from the vertical portion (502) to receive the bumper beam (201).

6. The three piece bumper beam structure (200) as claimed in claim 5, wherein the base portion (501) and the vertical portion (502) define a continuous bead (504) to prevent deformation of the bumper beam (201) during the Low speed impact.

7. The three piece bumper beam structure (200) as claimed in claim 5, wherein the vertical portion (502) and the top portion (503) define continuous beads (505, 506) at corners, wherein the continuous beads (505, 506) deform during pedestrian impact to absorb force of impact.

8. The three piece bumper beam structure (200) as claimed in claim 1, wherein the three piece bumper beam structure (200) is made of sheet metal.

9. The three piece bumper beam structure (200) as claimed in claim 1, wherein the bumper beam (201) is sheet metal portion expanding along front width of the vehicle.

10. The three piece bumper beam structure (200) as claimed in claim 1, wherein a bead (201a) is provided in middle of the bumper beam (201) to restrict to and fro movement of the bumper beam (201) in direction of vehicle length.
, Description:FRONT BUMPER BEAM STRUCUTRE FOR PEDESTRAIN SAFETY AND LOW SPEED IMPACT ENERGY ABSORPTION
FIELD OF INVENTION:
[001] The present subject matter described herein, relates to a front bumper beam structure for vehicle, and, in particular, to a three piece bumper beam structure of the vehicle to absorb impact energy thus protecting leg of pedestrian and protecting front end systems like lamps radiator, condenser during Low speed impact.
BACKGROUND AND PRIOR ART:
[002] Vehicle manufacturers are concerned with improving passenger safety and with reducing the cost of repairing vehicles in the event of impacts, while at the same time avoiding any significant increase in the weight of these vehicles.
[003] For pedestrian safety, in the event of a frontal impact, manufacturers are optimizing the various parts, such front bumper of the vehicle. The bumper system has an energy absorber which absorbs energy during pedestrian impact with the vehicle. There are several zones, such as upper leg and lower leg where vehicle hit the pedestrian. The upper leg energy absorber is provided at the upper side of the bumper where upper part of radiator is mounted. Further, the lower leg energy absorber is provided at lower side where lower part of the radiator is mounted. Along with the pedestrian safety, the manufactures has to protect the functional parts from the impact. Accordingly, the manufactures provide several stiffer zones in the bumper system to avoid transmission of impact energy to functional parts. The manufactures provide front extending member which extend along length of the vehicle and define engine cabin.
[004] However, given the limited space in motor vehicles, manufacturers, have to develop structures which guarantee a good level of energy absorption from the end of the vehicle up to the non-deformable zone while at the same time avoiding dead zones, that is to say zones which cannot deform axially and absorb significant deformation work.
[005] In order to reduce the cost of repair during low speed impact, the manufacturers modify the bumpers or the scuff moldings of the vehicles, particularly by strengthening the bumper beam and inserting deformable mechanical elements known as energy absorbers which are designed to crumple under a force which is appreciably lower than the force required to deform the bumper beam. But by adding energy absorbers in the bumper beam adds extra cost and weight to the bumper beams.
[006] Further, the existing bumper beams has box structure at the terminal ends to absorb impact energy during low speed impact and the frontal pedestrian impact. The box structures in the bumper beam have a plurality of parts which makes the structure more complex and costly. The bumper beam having the energy absorbers has to work efficiently in all direction with respect to angles of impact. To cater angles of the impact, the bumper beam has a plurality of crushable lobes along front surface of the bumper beam. In the system, quality of resin and placement of crushable lobes plays important role. Further, it adds extra cost and weight to the bumper beam system.
[007] In an attempt to satisfy these criteria, numerous solutions have been implemented to date, but they lead to an appreciable increase in the weight of the vehicle and in cost.
[008] One solution to avoid this drawback, energy absorbers are known which are made of aluminum, which allows the weight to be reduced, but their energy-absorption properties are generally not easy to control and often insufficient, while the material costs and cost of manufacture of such absorbers remain high.
[009] Further, the energy absorption box structures at terminal end is complex and required multiple parts. These box structures absorbs impact energy. However their cost of manufacture also remains very high and along with weight.
[0010] In order to improve the energy absorbing efficiency of the front bumper, sometime foam based absorbers are positioned in between the bumper and the vehicle long members.
[0011] Adding of these absorbers results in the cost and weight of the bumper assembly of the vehicle which reduces the overall efficiency of the vehicle. The existing energy absorbers are expensive and complex in designing and manufacturing. Therefore, there is a need in the art to have a bumper beam structure that can be more simple and inexpensive, and which can absorb the impact energy based on the location and force of impact imparted to the pedestrian's lower leg.
OBJECTS OF THE INVENTION:
[0012] The principal objective of the present invention is to provide a front bumper beam structure for absorbing impact energy in the event of pedestrian collision with vehicle front end.
[0013] Another object of the present subject matter is to provide a front bumper beam structure to protect front end components of engine cabin in the event of Low speed impact.
[0014] Another object of the present subject matter is to provide a three piece front bumper beam structure to compliance with pedestrian safety and low speed impact regulations.
[0015] Another object of the present subject matter is to provide a three piece front bumper beam having light weight.
[0016] Yet another object of the present invention is to provide a bumper beam structure which is simple and inexpensive, and efficiently absorbs the impact energy without major injury to leg of the pedestrian and front end components.
SUMMARY OF THE INVENTION:
[0017] The subject matter disclosed herein relates to a three piece bumper beam structure to protect pedestrian leg during impact of the vehicle with pedestrian and to protect front end systems, such as cooling unit or radiator or lamps during Low speed impact, The three piece bumper beam structure comprises a bumper beam, a right side terminal end bracket and a left side terminal end bracket. The bumper beam is joined in between the right side terminal end bracket and the left side terminal end bracket through spot welding. Further, the right side terminal end bracket and the left side terminal end bracket are mounted on long members of the vehicle body through bolts. The present three piece bumper beam structure is made from sheet metal thus having light weight and low cost.
[0018] In an embodiment, the terminal bracket whether right side or left side comprises a base portion, vertical portion and a top portion. The base portion has a plurality of mounting holes to mount the terminal end bracket on the long members of the vehicle body. The vertical portion extends at an angle from the base portion in upward direction. The top portion extends in perpendicular direction from the vertical portion to receive the bumper beam. The terminal brackets are mounted on the long members of the vehicle body. The terminal brackets have a bumper beam in middle which expands along width of the vehicle.
[0019] In order to further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit scope of the present subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0021] Fig. 1 illustrates mounting of front bumper beam on long members of the vehicle at front end, in accordance with an embodiment of the present subject matter;
[0022] Fig. 2 illustrates exploded view of three piece front bumper beam, in accordance with an embodiment of the present subject matter;
[0023] Fig. 3 illustrates assembled view of the three piece front bumper beam, in accordance with an embodiment of the present subject matter;
[0024] Fig. 4 illustrates structure of terminal end members of the three piece bumper beam structure, in accordance with an embodiment of the present subject matter;
[0025] Fig. 5a and 5b illustrates deformation pattern in the terminal end members during pedestrian impact, in accordance with an embodiment of the present subject matter; and
[0026] Fig. 6a and 6b illustrates deformation pattern in the terminal end members during Low speed impact, in accordance with an embodiment of the present subject matter.
[0027] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0028] The subject matter disclosed herein relates to a three piece bumper beam structure to protect pedestrian leg during impact of the vehicle with pedestrian and to protect front end systems, such as cooling unit or radiator or lamps during Low speed impact, The three piece bumper beam structure comprises a bumper beam, a right side terminal end bracket and a left side terminal end bracket. The bumper beam is joined in between the right side terminal end bracket and the left side terminal end bracket through spot welding. Further, the right side terminal end bracket and the left side terminal end bracket are mounted on long members of the vehicle body through bolts. The present three piece bumper beam structure is made from sheet metal thus having light weight and low cost.
[0029] In an embodiment, the terminal bracket whether right side or left side comprises a base portion, vertical portion and a top portion. The base portion has a plurality of mounting holes to mount the terminal end bracket on the long members of the vehicle body. The vertical portion extends at an angle from the base portion in upward direction. The top portion extends in perpendicular direction from the vertical portion to receive the bumper beam. The terminal brackets are mounted on the long members of the vehicle body. The terminal brackets have a bumper beam in middle which expands along width of the vehicle.
[0030] On the present energy absorber, a plurality of beads is provided on the complete surface of the energy absorber at equal distance along the length. Each of the beads from the plurality of beads is provided at equal distance from each other. Further, no hole is provided in the corner zone which gives highest stiffness to this zone. During the impact the corner zone requires higher stiffness compared to the central and middle zone so that pedestrian leg does not come in contact with hard structural members at corners.
[0031] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0032] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0033] FIGS. 1 to 3 illustrate the three piece bumper beam satisfying pedestrian safety and Low speed impact regulations of the present subject matter. The present three piece bumper beam can be mounted on any vehicle that meets the pedestrian safety regulations. The present beam structure is intended to reduce the impact force of a vehicle on a pedestrian when the pedestrian and vehicle impact. The present beam structure also reduces intrusion into the vehicle when the bumper and an object impact each other at Low speed, either when the object is a flat surface or an angled surface. The present beam structure can be mounted on the front frame or rear frame of a vehicle. In particular, the beam structure can be mounted on the bumper area of the front of the vehicle. In the present beam structure is mounted transversally on the vehicle along width of the vehicle.
[0034] Fig. 1 illustrates mounting of the present three piece bumper beam across width of the vehicle, in accordance with an embodiment of the present subject matter. The present assembly 100 includes two long members 103, 104 running along length of the vehicle. On the long members 103, 104, the three piece bumper beam structure is mounted with screws or bolts. The three piece bumper beam structure comprises three parts, i.e., bumper beam 101, right side terminal end bracket 102, and left side terminal end bracket 103. The bumper beam 101 is provided in between the right side terminal end bracket 102 and the left side terminal end bracket 103. Detail description of the three piece structure is explained in the figure 2. In an embodiment, the three piece bumper beam structure is mounted on front end of the vehicle to absorb impact energy from all directions during pedestrian impact with the vehicle.
[0035] Referring to figure 2 illustrating exploded view of the three piece bumper beam structure 200. The three piece bumper beam structure 200 includes a bumper beam 201, a right side terminal end bracket 203 and left side terminal end bracket 202. Both the right side terminal end bracket 203 and the left side terminal end bracket 202 are similar in shape, configuration and dimensions, therefore, hereinafter both can be interchangeably referred as terminal end brackets 202, 203. The bumper beam 201 is disposed in between the right side terminal end bracket 203 and the left side terminal end bracket 202. The bumper beam 201 is spot welded on the terminal end brackets 202, 203. The bumper beam 201 is provided transversally along width of the vehicle to cover complete width of the vehicle. The bumper beam 201 has a rectangular bead 201a along length of the bumper beam 201. The rectangular bead 201a provides strength to the bumper beam 201 and avoids to and fro motion of the bumper beam along length of the vehicle. The rectangular bead 201a helps to absorb force of impact in frontal Impact.
[0036] Referring to figure 3, the bumper beam 201 is joined with the terminal end brackets 202, 203 through spot welding. Further, the terminal end brackets 202, 203 having the bumper beam 201 in middle are mounted on the main body of the vehicle through bolts.
[0037] Referring to figure 5a, the terminal end bracket 500 includes a base portion 501 having a plurality of mounting holes 501a, 501b to mount the terminal end bracket 500 on the long members103, 104 of the vehicle body. A vertical portion 502 extends at an angle from the base portion 501 in upward direction. The angle is in range 45o to 120o, preferably 60o to 90o. Further, a top portion 503 extends perpendicularly in forward direction from the vertical portion 502 to receive the bumper beam 201. Other terminal bracket has similar structure and shape. The base portion 501, the vertical portion 502 and the top portion 503 define a ‘S’ shape terminal end bracket where end portions are flat to receive the bumper beam and to mount the terminal bracket on the long members of the vehicle. Referring to figure 4, the base portion 501 and the vertical portion 502 have a continuous bead 504 in shape of triangle to prevent deformation of the bumper beam 201 during the Low speed impact. The continuous bead 504 extends from the base portion 501 to the vertical portion 502. Further, the triangular continuous bead 504 has wider base or base in the base portion 501 and narrow portion in the vertical portion 502. In other words, the triangular continuous bead 504 tapered down from the base portion 501 to the vertical portion 502.
[0038] In an embodiment as disclose in the figure 4, the vertical portion 502 and the top portion 503 has continuous beads 505, 506 at corners to provide strength at corner to avoid sharp bending of the top portion 503. The continuous beads 505, 506 deform during pedestrian impact to absorb force of impact.
[0039] Referring back to figure 3 which illustrates impact of force in three directions, such as L1, L2 and L3. Where in , L2 and L3 represents the different impact load positions at the front of the vehicle.
[0040] In case of pedestrian impact at L1 L1, when the force acts on the bumper beam, the force transmits to the apron member or long members through terminal brackets 202, 203. The terminal brackets 202, 203 have mainly three continuous bead structures 504, 505, 506, as shown in the figure 4. In case of the pedestrian impact, the deformation happens in 505 and 506 simultaneously, absorbing the force of impact to protect the pedestrian leg. The present bead structures, i.e., 505 and 506 of the terminal brackets guides the deformation of the terminal bracket 500 in such a way so that energy is not transmitted to the pedestrian leg. Referring to figure 5b, the terminal bracket 500 is in straight position 507 before the pedestrian impact with the vehicle. After the pedestrian impact with the vehicle, the beads structure 505, 506 guides bending of the terminal bracket 500 towards inward direction to absorb impact energy. Reference numeral 508 shows the bending of the terminal bracket 500 toward inward direction.
[0041] In case of low speed impact atL2, the bead structure 504 acts as another element to absorb energy and guides the deformation in such a way that the bumper beam structure 201 is not bent towards the engine room side. This helps in protection of the Engine Cooling units.
[0042] In the event of Low speed impact at L3 the entire load is transferred laterally in the bumper beam structure 201. The continuous bead Structure 504 then prevents the deformation in such a way that the bumper beam 201 is not bent towards the engine room side. This helps in protection of the Engine Cooling units. The terminal end bracket bent in outward direction stretch the bumper beam so that the bumper beam do not hit the engine cooling unit. Figure 6a and 6b illustrate position of the terminal end bracket before and after impact. Reference numeral 601 shows structure of the terminal end bracket before impact and reference numeral 602 indicates structure of the terminal end bracket after the impact.
[0043] The present three piece bumper beam structure is made of sheet metal which results in light weight and low cost. Further, bead structures 504, 505, 506 can be provided on the terminal brackets easily by the pressing machine. Another advantage of the present three piece bumper beam structure is that if any part be it right side terminal end bracket, bumper beam, and left side terminal end bracket is damaged in corresponding side impact, during serviceability, only the damaged part can be replaced with fresh part other parts may remain same. Therefore, serviceability cost is reduced. Further, the present structure uses simple spot welding process to join the bumper beam with the terminal brackets which involve low cost.
[0044] In another embodiment of the present subject matter, the shape and number of bead structures in the terminal brackets can be optimized to provide more strength and stiffness to the terminal brackets.
[0045] The term “vehicle” or “Automobile” as used throughout this detailed description and in the claims refers to any moving vehicle that is capable of carrying one or more human occupants or Goods and is powered by any form of energy. The term “vehicle” is a motor vehicle which includes, but is not limited to: cars, trucks, vans, minivans, hatchback, sedan, MUVs, and SUVs.
[0046] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
[0047] Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.